condition monitoring

1. WELCOME

2. CONDITION MONITORING THROUGH NON DESTRUCTIVE TESTINGS OF MACHINES AND PLANTS PRESENTED BY : ANOOP GOPAL ROLL NO: 09 S7 MECHANICAL

5. CONDITION BASED MAINTENANCE 2.PREVENTIVE 3.PREDICTIVE 1.BREAK DOWN MAINTENANCE

6. NDE TECHNIQUES 1.VIBRATION MONITORING 2.ACOUSTIC EMISSION (AE) 3.INFRARED THERMOGRAPHY (IRT) 4.FERROGRAPHY 5.FIELD SIGNATURE MAPPING (FSM)

8. ANALYSIS OF RESULTS 1. VIBRATION CAUSE IDENTIFICATION Sl No FAULT FREQUENCY DIRECTION OF VIBRATION 1 ROTATING UNBALANCE SAME AS RUNNING SPEED RADIAL 2 MISALIGNMENT OF BEARINGS 2*SPEED RADIAL AND AXIAL 3 ROLLER BEARING DEFECT AT BALL OR ROLLER SPEEED ULTRA SONIC FREQUENCIES(20-60KHz) RADIAL AND AXIAL 4. OIL FILM WHIRL IN HIGHSPEED TURBO MACHINES 0.5*SPEED RADIAL 5 DAMAGED OR WORN GEARS No: OF TEETH* RPM RADIAL

9. VIBRATION METER (HAND HELD) Vibration Meter : for imbalance, structural weakness, loose parts etc INDUSTRIAL MACINERY CLASSIFICATION Class 2: Medium size machines without special foundation Class 3: Large machines on rigid foundations Class 4: Large machines on soft foundations. SPM VIB-11 by SKF

12. GROWTH THROUGH CBM ACTIVITIES AT RSP No: of machines BREAK DOWNS PREVENTED-10-102 EQUIPMENTS INCLUDED - 40-140 year

13. ACOUSTIC EMISSION MONITORING AE sensors respond with amazing sensitivity to motion in the low ultrasonic frequency range (10 kHz - 2000 kHz). Motions as small as 10 -12 inches and less can be detected

14. ACOUSTIC-EMISSION METHOD This method is based on the registration of the elastic compression waves that are emitted by the defects developing in the stressed constructions.

19. r aw thermo graphic data. data after removing the noise and vertical gradient. data processed for the local gradient in surface temperature. CASE STUDY high strength welds Fig setup for infrared testing of lap joints correspond to low strength welds.

21. HOW IS THE TEST PERFORMED Tests Conditions Detected # Abnormal Wear Fuel Dilution Dirt Water Coolant Incorrect Oil Oxidation Additive Depletion Glycol Test * Viscosity * * Appearance/Odor * * * * * Spectrometric Analysis * * * * Alkaline Reserve * * Blotter Spot Test * * * Water Content * Distillation * Flash Point *

22. WEAR METAL ORIGIN TABLE METAL WEAR POSSIBLE ORIGIN. ALUMINIUM BEARINGS,BLOCKS,BLOWERS,BUSHINGS, CLUTCHES,PISTONS. CHROMIUM BEARINGS,PUMPS,RINGS,RODS. COPPER BEARINGS,BUSHINGS,CLUTHES,WASHERS. IRON BLOCKS,CRANK SHAFTS, CYLINDERS,DISCS. SILVER SOLDERS. TIN PISTONS.

23. MEASURING INSTRUMENT ModelT2FMAnalytical Ferrograph . Bi chromatic microscope. Video camera. Video capture card. Image capture software. industrial standard personal computer . This measure the effects of Contamination and electro-chemical changes that occur in synthetic and petroleum based oils

25. FIELD PATTERN Sensing pins (electrodes) in an array over the monitored area to detect changes in the electrical field pattern. The voltage = the signature . Graphical plots indicating the severity and location of corrosion, and calculates actual corrosion and metal loss

26. INDUSTRIAL ARRANGEMENT A typical refinery monitors high temperature areas such as heater bends in the distillation unit.

27. CONCLUSION

28. SUMMARY OF APPLICABILITY AND CAPABILITY OF VARIOUS NDT TECHNIQUES NDT TECHNIQUE DETECTION CAPABILITY NON CONTACT INSPECTION AUTOMATED INSPECTION DEFECT SIZING VIBRATION VOLUMETRIC POSSIBLE POSSIBLE POSSIBLE ACOUSTIC EMISSION VOLUMETRIC POSSIBLE POSSIBLE NOT POSSIBLE I R THERMO- GRAPHY SURFACE , NEAR SURFACE POSSIBLE POSSIBLE POSSIBLE FERROGRAPHY VOLUMETRIC POSSIBLE POSSIBLE POSSIBLE F S M SURFACE, NEAR SURFACE POSSIBLE POSSIBLE POSSIBLE

29. THANK YOU